Continuous platform cutting apparatus

ABSTRACT

An apparatus for shaping a slab of compressible or cellular polymer material ( 80 ), such as polyurethane foam, shapes such slab by cutting portions of the material from one surface. A moving patterned platform ( 32 ), preferably an endless belt or a series of interconnected panels, is interposed between a compression roller ( 56 ) and a cooperating surface ( 18 ) and defines at least one recess ( 36 ) or at least one projection ( 320 ) or a combination of recesses and projections. When the slab is compressed between the compression roller and the platform, which is supported by the cooperating surface, a portion of the material fills the recess or recesses in the moving platform. At least a portion of the compressed material within the recess(es) is then cut from the surface of the slab by a blade ( 76 ) just as the slab emerges from between the compression roller and the platform, leaving a profile-cut surface with cut-out portion(s) corresponding in pattern and shape to the recess(es) provided in the moving patterned platform. Alternatively, a portion of the material is forced away form the blade ( 76 ) by the projection or projections ( 320 ) so that a portion of compressed material is not cut by the blade ( 76 ).

This application is a continuation-in-part of U.S. Ser. No. 08/899,292,filed Jul. 23, 1997, now U.S. Pat. No. 6,546,836, and is a continuationin part U.S. Ser. No. 08/899,398, filed Jul. 23, 1997, now U.S. Pat. No.6,142,053.

BACKGROUND OF THE INVENTION

The present invention relates to apparatus for continuously shaping thesurface of a slab of compressible or cellular polymer material, such aspolyurethane foam. A blade cuts portions of the compressible materialfrom the surface of the slab after the slab is passed through apredetermined gap and has been compressed between a compression rollerand a movable patterned platform. The predetermined gap preferably iscreated at a region where the platform is adjacent to or driven by adrive roller.

Several methods and apparatus for cutting slabs of cellular polymermaterials have been disclosed in the prior art. For example, U.S. Pat.No. 4,700,447 to Spann discloses convolute-cutting slabs of polyurethanefoam by compressing a slab or pad of foam between a pair of rolls withopposed spaced projecting fingers arranged in a pattern and cutting thefoam with a saw blade transversely just as it emerges from the rolls.The cut slab is then separated into two pads each with convolute-cutsurfaces forming a series of peaks separated by valleys. The valleysformed on one pad are formed by slicing away foam which becomes a matingpeak or projection on the other pad. Spann then shaves the peaks to forma more planar top surface. As noted in Spann, convolute cutting aloneproduces only rounded peaks and rounded valleys, and it is difficult, ifnot impossible, to produce a cut surface with peaks having substantiallyflat top surfaces or with recesses having substantially straight sidewalls. The convolute usually is intended to form the classic symmetricaland repeating “egg crate” pattern of peaks and valleys. To achieve aplanar upper surface at other than the recessed portions the tops of thepeaks must be cut or shaped in a second step.

Compressible cellular polymer materials may also be cut using a hot wirecutter. A slab of such material is cut by moving the slab relative toone or more hot wires as shown, for example, in U.S. Pat. No. 4,683,791(Demont). Only straight cuts in regular or symmetrical patterns may beformed using a hot wire cutter. See also U.S. Pat. No. 4,915,000(MacFarlane) and U.S. Pat. No. 5,573,350 (Stegall).

Shapes may be cut into the surface of a slab of cellular polymermaterial using a punch cutting apparatus, such as disclosed in U.S. Pat.No. 5,299,483 (Ber-Fong). A block of the cellular material is pressedagainst a template so that a portion of the material is forced throughan opening in the template. The exposed material is then cut by a bladeand removed, leaving a recess or cavity in the slab. This method cutsone block of material at a time, and only one surface at a time.

U.S. Pat. No. 4,351,211 (Azzolini) compresses a block of foam materialagainst a template or die having an aperture therein using a pair ofplates with concave and convex portions. The compressed foam istransversely cut along the template as it is held between the plates.More complex cut regions may be obtained than when using a templatewithout the plates with raised and depressed portions, but only oneblock is cut at a time. Other template or pattern cutting methods areshown in U.S. Pat. No. 3,800,650 (Schroder) and U.S. Pat. No. 3,653,291(Babcock).

The surface of a cellular polymer material may be shaped by molding orembossing, as opposed to cutting. U.S. Pat. No. 4,383,342 (Forster), forexample, discloses injecting the foam-forming composition into a moldcavity. After sufficient curing time, the individual foamed article isremoved from the mold. Other one-shot molding techniques and apparatusare known to persons of skill in the art. The molded cellular polymerproduct generally forms a tough skin at the surfaces that were incontact with the mold.

Continuous and semi-continuous molding processes are also known. Theseprocesses have the same drawbacks associated with one-shot moldingtechniques. For example, U.S. Pat. Nos. 4,128,369 and 4,290,248(Kemerer, et al.) disclose an apparatus and method for impressionmolding thermoplastic products. The thermoplastic material in a liquidstate is injected between compressed traveling belt molds. As the beltmolds travel away from the point of introduction of the thermoplastic,they are cooled, which in turns cools the thermoplastic material,allowing it to solidify. The hardened molded thermoplastic material isremoved from between the belts to form the finished product. Kemererdoes not show a method for cutting or shaping a cellular polymermaterial, such as polyurethane foam.

A method of embossing a foam surface using a patterned metallicembossing belt or band is shown in U.S. Pat. No. 4,740,258(Breitscheidel). The foam is heated and then pressed against theembossing belt. The belt is removed after the foam surface cools. Theembossed surface by design has a hardened skin. No method for cutting orshaping the foam is disclosed.

U.S. Pat. No. 5,534,208 (Barr) discloses a continuous rotary method forsurface shaping synthetic foams in which the foam is compressed betweena compression roller and a die roller having raised and recessedportions. The portions of the foam extruded into the recesses in the dieroller are cut away. The compressed foam portions return to anuncompressed state after passing through the rollers. As a result, amirror-image pattern to the pattern on the surface of the die roller iscut on the surface of the foam. The diameter of the die roller limitsthe length of the shaped synthetic foam article that may be formed.

The prior art does not disclose an apparatus for continuously shaping acompressible or cellular polymer material of unlimited length by cuttingto form recesses of various depths and various symmetrical andnonsymmetrical shapes. Nor does the prior art disclose a profile cutproduct without the hardened skin or hard spots associated with moldedor embossed products. Nor does the prior art disclose continuouslycutting compressible or cellular polymer materials with an apparatusthat includes a movable patterned platform, such as an endless belt or aseries of connected panels defining at least one recess or void intowhich the cellular material may be compressed before cutting thematerial transversely with a knife blade.

SUMMARY OF THE INVENTION

An apparatus for continuously shaping a compressible or cellular polymermaterial, such as polyurethane foam, by cutting and removing portions ofthe material is disclosed. A compression roller and a cooperatingsurface, such as the surface of a driver roller, compress a slab ofcellular polymer material. A surface of the moving patterned platform,interposed between the compression roller and the cooperating surface,defines one or more recesses or voids that hold a portion of thecellular material as it is compressed by the roller. In a preferredembodiment, the cooperating surface is the solid surface of a driveroller. In a less preferred embodiment, the moving patterned platform isinterposed between the compression roller and a follower roller and thecompression force is applied at a region where the platform is adjacentto a solid surface of the follower roller.

A knife blade is positioned downstream from the compression roller andthe point at which the compression force is applied, preferably with theblade interposed between the compression roller and the patternedplatform. The slab surface is cut transversely by the blade just as theslab emerges from between the compression roller and the movingpatterned platform, thus trimming off those portions of the cellularmaterial that filled the recesses or voids in the patterned platform. Inan alternate embodiment, the blade is positioned so that it shaves afine scrim layer of foam from the slab surface, and makes deeper cutsinto the slab in the regions in which the polymer material has filledthe recesses or voids, but preferably the blade cuts away foam materialonly from those portions of the surface at which it is intended thatvoids or recesses be formed. If the patterned platform definesupstanding projections, instead of or in addition to recesses, theprojections force a portion of the foam material away from the blade andless material is cut from the slab surface in those regions.

The patterned platform may be an endless belt or a series of movablepanels or plates or any other structure that may travel in a continuouscircuit or path. Where the patterned platform is an endless belt, thebelt is placed over a series of rollers wherein at least one such rolleris motor driven. The belt may be engaged to the drive roller withinterconnecting gears or ribs so that the rotation of the drive rollercauses the belt to travel. Where the patterned platform is formed by aseries of interconnected panels, such as metal plates, the panelspreferably are connected movably to a chain and sprocket drive system.Thus when the sprocket is driven, such as by a motor, the sprocketdrives the chain and the panels interconnected to the chain.

The patterned platform may define at least one recess, which may be ahole or void through the platform, but preferably is a cut-out portionthat does not pass through the entire thickness of the platform. Therecess may be provided as a simple or complex geometric shape. Wheremore than one recess is defined in the platform, the recesses may be ofthe same or different shapes, may be interconnected or separated, may besymmetrical or nonsymmetrical, and may be repeating or non-repeating onthe patterned surface of the patterned platform. The recesses may be cutto different depths in the platform. Several separate series ofdifferent recesses may be provided on one patterned platform.

The patterned platform may define at least one upstanding projection.The projection may be provided as a simple or complex geometric shape.Where more than one projection is defined on the platform, theprojections may be of the same or different shapes, may beinterconnected or separated, may be symmetrical or nonsymmetrical andmay be repeating or non-repeating on the patterned surface of thepatterned platform. The projections may have different heights. Thepatterned platform may include a combination of recesses and upstandingprojections.

As the slab travels with the patterned platform and is compressedbetween the compression roller and patterned platform (with recesses), aportion of the cellular material fills the recesses or voids in thepatterned platform. Greater amounts of cellular material are cut fromthe slab in regions that have been compressed into the recesses or voidsin the patterned platform because this material has been forced to oneside of the cutting edge of the blade in these regions. The cut portionsare removed from the slab after it passes the knife. The resultingprofile cut product has on its cut face a series of cut regions thatsubstantially correspond in pattern and shape in mirror image to therecesses or voids provided in the patterned platform. The cut regions inthe slab are also cut deeper in those regions that correspond to thedeeper recesses in the patterned platform. However, due to the varyingcompression factors for cellular polymer materials, the depth of cut ofthe cut regions usually is not identical to the depth of cut of therecesses within the patterned platform.

Preferably, the compression roller is motor driven. The patternedplatform is also preferably motor driven.

The cut foam product has a series of recesses or projections defined inits surface. If the drive roller drives the patterned platform at onespeed and the compression roller is driven at a different speed, theblade cuts the foam material to form angled sidewalls that are greaterthan or less than 90° as measured from the base of a cut recess or thetop surface of a projection formed on the surface of the cut foam slab.The difference in platform speed as compared to the compression rollerspeed causes one surface of the slab to enter the predetermined gapprior to the other surface of the slab.

Using the apparatus according to the invention, a profile cut cellularproduct in which portions have been cut from both the upper and lowersurface may be formed by feeding the slab through the apparatus twice.First one surface is cut, then the cut product is inverted and fedthrough the apparatus a second time to cut its opposite surface.

DESCRIPTION OF THE FIGURES

Numerous other objects, features and advantages of the invention shallbecome apparent upon reading the following detailed description taken inconjunction with the accompanying drawings, in which:

FIG. 1 is a schematic perspective view of one embodiment of thecontinuous platform cutting apparatus of the invention;

FIG. 2 is a cross-sectional view taken along line 2—2 of FIG. 1;

FIG. 3 is a side elevational view of the embodiment of the inventionshown in FIG. 1;

FIG. 4 is a schematic perspective view of an alternate moving platformfor the continuous platform cutting apparatus of the invention;

FIG. 4A is a schematic perspective view of an alternate configurationfor the alternate moving platform of FIG. 4;

FIG. 5 is a fragmental side elevational view of a cellular polymerunderlayment mat defining patterned recesses that have been cut into themat using the continuous platform cutting apparatus of the invention;

FIG. 5A is a fragmental side elevational view in cross-section takenalong line 5—5 of FIG. 5;

FIG. 6 is a top plan view of the mat of FIG. 5;

FIG. 7 is a schematic side elevational view in partial cross-sectionshowing a second embodiment of a continuous platform cutting apparatusaccording to the invention;

FIG. 8 is a partial schematic side elevational view in partialcross-section showing a modification to the second embodiment of FIG. 7;and

FIG. 9 is a partial schematic side elevational view in partialcross-section showing a third embodiment of a continuous platformcutting apparatus of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring first to the embodiment of the invention as shown in FIGS.1-3, a continuous platform profile cutting apparatus for compressible orcellular polymer materials is supported on a first frame structure 12and second frame structure 22. A shaft 14 is mounted for rotation to thefirst frame structure 12, preferably with bearings. A motor 16 drivesthe shaft 14. A drive roller 18 is mounted on shaft 14. The outersurface of the drive roller 18 may be covered or coated with a slipresistant material, such as urethane. Ribs or gear teeth 20 are providedaround the outer end or peripheral end surfaces of the first driveroller 18. Alternatively, separate gears with suitable gear teeth may beprovided at each end of the first drive roller 18.

Shaft 24 is mounted for rotation to the second frame structure 22,preferably using bearings. A first follower roller 28 is mounted onshaft 24. The outer surface of the first follower roller 28 may becovered or coated with a slip resistant material, such as urethane.

A patterned platform, such as endless patterned belt 32, has a patternedfacing surface 34 and an opposite surface 38. Belt 32 is mounted aroundthe drive roller 18 and first follower roller 28. The belt facingsurface 34 defines recesses 36, which may be simple or complex shapes,simple geometric patterns, complex patterns, symmetrical or repeatingpatterns or non-symmetrical and non-repeating patterns. Rectangular 36and circular 37 recesses are shown by way of example in FIG. 1. Therecesses may be provided at various depths as discussed in more detailbelow.

Mating ribbed sections 39 on the outer edges of the belt oppositesurface 38 mate with or engage the ribs or gear teeth 20 provided on thedrive roller 18. When the motor 16 drives shaft 14, which in turnrotates drive roller 18, the endless belt 32 travels around the driveroller 18 and the first follower roller 28. The mated ribbed sections 39and ribs 20 and the frictional engagement between the contactingsurfaces of the belt with the rollers keep the belt centered and alignedwith the rollers as it travels a path around the rollers.

First idler roller 40 is mounted for rotation on shaft 42 which is heldby a portion 44 of the frame 12. First idler roller 40 is positioned ata point between the drive roller 18 and the first follower roller 28 tostabilize the movement of the endless belt 32.

Compression roller 46 is provided at a point between the drive roller 18and the first follower roller 28. The compression roller 46 is mountedfor rotation on shaft 48. The shaft 48 is held in a bearing recesswithin a frame 52. Tension adjusting means 54, such as a fluid cylinderor spring or series of springs, may act on frame 52 to adjust thecompression force applied.

The outer surface 47 of the compression roller 46 contacts the oppositesurface 38 of the belt 32 on which the ribbed portions 39 are provided.The outer surface 47 of the compression roller may be covered or coatedwith a slip resistant material, such as urethane. As shown best in FIG.2, the surface 47 of the compression roller 46 does not extend to thefull outer periphery of the roller, leaving a recess into which theribbed portions 39 extend so that the surface 47 of the roller 46contacts the surface 38 of the belt 32. Greater slip resistance resultswhen the amount of surface engagement between the belt 32 and the rollercompression surface 47 is increased.

Compression roller 56 with outer compression surface 60 is mounted forrotation on shaft 58. The shaft 58 is held within frame 62. A motor 57drives shaft 58. The roller 56 is separated from compression roller 46,leaving a space or gap through which the endless belt 32 travels betweenthe compression surfaces of the rollers. The arrow 64 in FIG. 2indicates the force applied against the frame 62 to urge roller 56 totoward roller 46.

Referring to FIG. 3, knife blade or band saw blade 76 is held withincasing 74. The blade 76 must have a sharp tip that is sufficiently sharpto cut transversely slabs of cellular polymer materials, such aspolyurethane foams. Because the blade 76 construction is known andunderstood by persons of skill in the art of cutting cellular polymermaterials, such as polyurethane foams, it will not be described indetail.

The blade 76 is positioned adjacent to the compression rollers 46, 56 sothat the sharp tip of the blade is at the output side of the rollers andadjacent to or just beyond the point at which the outer surfaces 47, 60of the compression rollers 46, 56 act to their greatest extent tocompress material that is placed between the rollers (i.e., thepredetermined gap). The blade 76 is also positioned between thecompression surface 60 of compression roller 56 and the patterned facingsurface 34 of endless belt 32 so that the blade tip is close totangential contact with the facing surface 34. The blade 76 should bepositioned so that it will not cut the compression surface 60 of theroller 56 or the patterned facing surface 34 of the belt 32. The blade76 should not interfere with the rotation of the rollers 46, 56 or themovement of the belt 32. Blade orientation may be adjusted so that thetip of the blade is moved closer or farther from the nip between roller46 and roller 56.

In one embodiment as shown best in FIGS. 2 and 3, as a slab 80 ofcellular material, such as polyurethane foam, is fed between thecompression surface 60 of compression roller 56 and the patterned facingsurface 34 of the endless belt 32, the slab 80 is compressed by therollers 46, 56. When the slab 80 travels into the nip or space orpredetermined gap between the rollers 46, 56, portions of the compressedslab material are held within the recesses 36 defined within the facingsurface 34 of the belt 32.

Knife blade 76 cuts transversely portions of the slab 80 just as theslab 80 emerges from between the compression rollers 46, 56. As shown inFIG. 3, the cuts into the slab 80 are made in the regions correspondingto those regions in which slab material had been compressed withinrecesses 36 defined in the facing surface 34 of the belt 32. A portionof the material that was held within a recess in the belt is cut awayfrom the slab before the compressed cellular material is able to recoverto its uncompressed state as it emerges from the compression rollers.Portions of the slab surface not compressed into the recesses or voidsin the facing surface 34 of the belt 32 may or may not be cut, dependingupon the position of the blade 76.

After the slab is cut as it emerges from the rollers, the cut-awayportions 88 are removed as waste in this example, leaving a resultingprofiled cellular material 90. The resulting product 90 has recesses 92substantially corresponding in shape to the recesses 36 provided in thepatterned face surface 34 of the endless belt 32. Slabs of cellularmaterial may thus be provided with profiled surfaces with an endlessarray of patterns, whether symmetrical or nonsymmetrical, simple orcomplex, or repeating or nonrepeating. For example, alternatively thecut-away portion 88 might be a separate profiled cellular materialproduct 90.

Preferably, only portions of the slab that have been compressed intorecesses or voids are cut away, resulting in less waste to remove fromthe surface of the slab as it emerges from the cutting apparatus. Incontrast to prior cutting methods, the waste material does not fall awayand contaminate the apparatus, but is carried away by the belt 32. Thewaste may then be swept or vacuumed off the belt as it continues totravel along its path defined by the rollers 18, 28.

Long slabs of cellular material may be fed continuously into and shapedby the continuous platform cutting apparatus. The apparatus may be usedto cut multiple products continuously from a single slab of material.The recesses and/or projections formed in a single patterned platformmay be arranged in separate configurations for different products.Alternately, repeating recess patterns may be formed in the patternedplatform. In addition, patterned platforms of different lengths may beused to form finished cut products of different lengths.

An example of a profile-cut product 300 made according to the inventionis shown in FIGS. 5 and 6. The profile cut product 300 represents acellular polymer insulating barrier or underlayment that will beinstalled in the interior of a motor vehicle between the floor surfaceand the carpeting. The upper surface 310 of the underlayment has beencut to provide complex patterns of recesses or voids. As shown in FIG.6, generally rectangular-shaped recesses 312 have been cut into thesurface of the product 300. In addition, more complex shaped recesses,such as interconnecting generally oval-shaped recesses 314 andinterconnecting straight-edged and curved-edged recesses 316, may be cutinto the cellular material. For the underlayment for a motor vehicle,preferably one surface, here what has been referred to as the uppersurface 310, is cut and the opposite surface remains uncut. The cutsurface of the underlayment is placed adjacent to the motor vehiclesurface so that the voids and recesses in the underlayment mate withshaped portions projecting from the vehicle surface. In this manner, theunderlayment may be provided so as to match the contour of the vehicleinterior surface. Once the underlayment is installed in the vehicle,carpet or other covering may be installed adjacent to the uncut andgenerally smooth surface of the underlayment.

The depth of the recesses 36, 37 of the belt 32 are typically a smallfraction of the depth of the corresponding cuts to be made in thesurface of the foam material 80. Because of the compression factor ofthe foam against the pattern belt 32, a shallow depression 36, 37 in thepattern belt 32 yields a much deeper depression in the foam. Forexample, a ⅝ inch thick sheet of foam material compressed against adepression 36 of 20 thousands of an inch in the patterned belt, in theapparatus 10 described above, yielded approximately a ½ inch deepdepression in the foam sheet 80. The spacing between the belt surface 34and the roller surface 56, if all other factors are equal, determinesthe compression factor of the foam and consequently the ratio ofpatterned belt depth to foam cut depth. The depth of cut in the foam canbe reduced for a given pattern belt recess depth or projection height byincreasing the spacing between the roller surface 56 and the beltsurface 34, thus reducing the compression factor.

Where the belt 32 is driven at the same speed as the roller 56, the cutproduct has recesses (or projections) formed with sidewallssubstantially perpendicular (90°) to the top surface of the product. Theangle of the cut sidewalls may be varied by driving the belt 32 at adifferent speed than the speed roller 56 is driven. When different drivespeeds are used, one surface of the slab 80 will enter the predeterminedgap before the other surface. The drive speed may be adjustedcontinually as the foam material slab 80 is introduced into the gap. Inthis way, sidewall angles may be the same or different in differentregions of the cut-product. Referring to FIG. 5A, the recess is cut withsubstantially perpendicular (90°) sidewalls 340, but there is shown inphantom outline a recess cut with angled side walls 342. When thecompression roller is driven at 25 feet per minute surface speed and thepatterned platform runs at 35 feet per minute surface speed, the cutproduct has recesses with side walls cut at an angle of about 110° to115°. However, the cut angle is about 90° when both surfaces are drivenat the same speed.

For certain applications, it may be desired to cut both the upper andlower surfaces of a slab of cellular material. If the embodiment of theinvention shown in FIGS. 1-3 is used for this purpose, once the slab hasbeen fed between the compression rollers and cut on one side, the slabmay then be inverted and fed between the compression rollers so that itmay be profile-cut on the opposite surface.

The endless belt 32 preferably is formed from a flexible material suchas rubber or silicone rubber or urethane. The belt 32 is thick enough towithstand the compressive forces, preferably about 0.375 inches or more,and has a durometer of about 35 or higher, preferably 75 or higher, mostpreferably at least 90. Alternatively, the belt may be formed offiberglass reinforced polyurethane or other composite materials suitablefor endless belts.

As shown in FIG. 4, rather than using an endless belt, the patternedplatform 200 may be constructed as a continuous or endless series ofinter-linked panels driven by chain and sprocket. The series of plates208, preferably formed from metal or other sturdy substrate, are mountedon shafts 210. The shafts 210 are held for rotation within bearingsleeves 212. Y-shaped follower bars 214 are connected at one end to theshafts 210 and at the other two ends to pin members 204 holding togetherthe links 202 of a chain. The chain links 202 are driven by sprockets(not shown), which in turn are driven by motors (not shown).

The plates 208 may define one or more recesses 216, or portions ofrecesses 216 a. The recesses may be cut through a portion or through theentire thickness of a plate. The recesses may be formed in rectangular,circular or other geometric shape. The recesses may be cut innon-uniform, non-symmetrical and not repeating shapes. The recesses neednot be contained wholly within a single plate. Rather, a recess definedby one plate may complement the recess defined by an adjacent plate toform larger or more complex recess shapes.

When a series of plates are used as the patterned platform, the slab ofcellular material will be pressed against the plates by a compressionroller (not shown in FIG. 4) so that a portion of the material iscompressed into the recesses in the plates and is cut away from the slabby a knife blade just as the cellular material emerges from thecompression roller. A support platform 222 is provided below the plates208 to support the plates when compression forces are exerted on them bythe compression roller.

FIG. 7 shows a preferred embodiment of the invention. Like referencenumerals in FIG. 7 refer to like elements as shown in FIGS. 1-3 becausethe apparatus 300 in FIG. 7 is similar to the apparatus 10 shown inFIGS. 1-3. There is provided a drive roller 18 that travels in thedirection indicated by the arrow 302. The outer surface of the driveroller 18 is provided with teeth 20. The apparatus also includesfollower roller 28.

A belt 32 has a patterned surface 34 with one or more recesses 36 andhas an opposite surface 38. Mating ribs or teeth 39 are proved on theopposite surface 38 of the belt. The teeth 39 engage the teeth 20provided on the drive roller 18. As the belt travels along a path aroundthe drive roller 18 and follower roller 28, it also contacts the outersurfaces of first and second idler rollers 40, 40′.

A compression roller 56 mounted on a shaft 58 is provided with an outersurface 60. In this apparatus 300, the compression roller 56 ispositioned close to the outer surface of the drive roller 18 to define apredetermined gap between the outer surface 60 and the roller 18. Theroller 56 position is adjustable, such that the outer surface 60 of theroller may be closer or farther from the outer surface of the driveroller 18 to change the gap. The belt 32 travels between the outersurface 60 of the compression roller 56 and the outer surface of thedrive roller 18.

A slab of compressible material 80 is fed into the gap between thepatterned surface 34 of the belt 32 and the outer surface 60 of thecompression roller 56. The gap is set to a distance that causes thecompressible material to be compressed between the outer surface 60 ofthe compression roller 56 and the patterned surface 34 of the belt 32.Portions of the compressible material are forced into the recesses 36formed into the patterned surface 34 of the belt 32.

A knife blade 76 held within knife casing 74 is positioned justdownstream from the gap. Just as the compressible material 80 passesthrough the gap, portions of the slab 80 held within the recess 36 arecut by the blade 76. The cut slab emerges with a profile-cut surfacewith recesses. The cut-away portions 88 are separated from the slab 80and are carried away by the belt 32 to be removed, either by fallingaway, by manual removal or by vacuum.

The apparatus in FIG. 8 shows a modification 300′ to the apparatus ofFIG. 7. To more smoothly compress the slab 80 of compressible materialbetween the compression roller 56 and the moving patterned belt 32,idler rollers 304 and 306, and a follower roller 308 are provided. Abelt 310 travels in a circuit defined by the compression roller 56 andthe follower roller 308 and idler rollers 304, 306. A narrowing gap isdefined between the belt 310 and the belt 32. The gap is widest betweenthe follower roller 308 and the belt 32 and progressively narrows orcloses between the idler roller 306 and the belt 32 and between theidler roller 304 and the belt 32. As the slab 80 passes between the belt32 and the belt 310 and through the progressively narrowing gap, thecompressible material is compressed to a greater degree, until thegreatest compression in the predetermined gap between the compressionroller 56 and the belt 32.

FIG. 9 shows another modification 300″ of the apparatus of FIG. 7,wherein a belt 32′ is modified to include raised projections 320projecting from the patterned surface 34′. Some cut products are formedby cutting away a scrim or thin layer from the surface along the entirelength of the slab 80. With projections 320 provided on the belt 32′,cut products can be formed without cutting away material where portionsof the slab passing through the predetermined gap are held to one sideof the blade 76 by the projections 320. Idler roller 40′ contacts thesurface of belt 32′ and a further idler roller 40″ is placed in contactwith the slab 300″ on the slab surface which is not in contact with thebelt 32′.

The apparatus according to this invention might be used to make profilecut products for a variety of end uses. In addition to motor vehiclecarpet systems, profile cut products might be made for other vehicleinterior applications, such as headliners, side panels and dash panels.Profile cut products might also be used for mattresses, mattress pads,pillows, furniture cushions, filters, sports equipment, footwearcomponents and packaging. The above list is intended to berepresentative and not exhaustive as to all the possible applicationsfor the invention.

While preferred embodiments of the invention have been described andillustrated here, various changes, substitutions and modifications tothe described embodiments will become apparent to those of ordinaryskill in the art without thereby departing from the scope and spirit ofthe invention.

I claim:
 1. An apparatus for shaping a slab of cellular polymer materialby cutting and removing portions of the material from an outer surfaceof the slab, comprising: a compression roller and a drive roller, saidcompression roller rotatable on an axis and having its outer surfacespaced apart from the drive roller to define a predetermined gaptherebetween so that the compression roller exerts a compressive forceagainst the slab of cellular polymer material as said slab is passedthrough said gap between the compression roller and the drive roller; acontinuous patterned platform driven by the drive roller, said patternedplatform having an outer surface and being interposed in the gap betweenthe compression roller and the drive roller and moveable with relationthereto, said outer surface of said patterned platform defining at leastone recess to receive a portion of the cellular polymer material when aregion of the slab is passed through said gap and compressed between thecompression roller and the drive roller, wherein the at least one recesshas a predetermined depth, and a blade for cutting the cellular polymermaterial as the slab emerges from the gap between the compression rollerand the drive roller; said blade positioned adjacent to the gap and tothe outer surface of the patterned platform to cut a portion of thecellular material received within the recess of the patterned platform.2. The apparatus of claim 1, wherein the patterned platform is anendless belt.
 3. The apparatus of claim 2, wherein the outer surface ofthe belt defines a plurality of said recesses.
 4. The apparatus of claim3, wherein the plurality of recesses defines a non-symmetrical,non-repetitive pattern.
 5. The apparatus of claim 1, wherein thepatterned platform has a set of ribs that engage a mating set of ribs onthe drive roller so that the rotation of the drive roller drives theplatform.
 6. The apparatus of claim 5, wherein a motor drives the driveroller and the drive roller causes the platform to travel at a speedsynchronized with the speed at which the outer surface of the driveroller is driven.
 7. The apparatus of claim 5, wherein a motor drivesthe drive roller and causes the platform to travel at a speed differentfrom the speed at which the outer surface of the compression roller isdriven.
 8. The apparatus of claim 1 further comprising: at least onefollower roller; and a belt that travels in a circuit defined by thecompression roller and the follower roller and is interposed between thecompression roller and the outer surface of the patterned platform, andwherein the follower roller is positioned upstream from the gap so thatthe slab of cellular polymer material is compressed between the belt andthe moving patterned platform before it enters the gap.
 9. The apparatusof claim 8, wherein the belt travels along a path defined by thefollower roller and a series of idler rollers spaced apart from theplatform at varying distances.
 10. The apparatus of claim 9, wherein thebelt defines a cooperating surface with respect to the platform andtravels along a path defined by the series of idler rollers, and whereinthe belt is spaced apart from the platform at varying distances.
 11. Theapparatus of claim 1, wherein the blade is positioned substantiallytangent and closely adjacent to the outer surface of the patternedplatform so that material is cut from the slab solely from the portionof the cellular material that is received within the recess of thepatterned platform.
 12. The apparatus of claim 1, wherein the blade ispositioned adjacent to but not substantially tangent to the outersurface of the patterned platform so that a layer of material is cutfrom the entire surface of the slab and a greater amount of material iscut from the slab from the portion of the cellular material that isreceived within the recess of the patterned platform.